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Best Practices for Coating and FRP Inspections
Michael P. Yee [email protected]
NACE Coating Inspector Level 3 #50795
Richard Taraborelli P.E. [email protected]
RTConults PLLC AMI Conference: June 10, 2015
• Common issues with the longevity of coatings and FRP linings.
• Case Studies with successful FRP construction.
• The value of knowing what you are receiving.
Table of Contents
Industry Standards
• API- Applies mainly corrosion with steel and insulation.
• NACE/SSPC- the main publications for surface preparation and coating/lining application.
• ASME- Composites mainly with FRP
• ICRI- Concrete coatings and repair.
• ISO- International equivalent of NACE
Coating and Linings
In the realistic world:
Surface Preparation Issues (+50% failures easily)
Ambient Conditions/Application
Wrong specification for environment
50%
20%
30% 30%
Failures
Surface Prep. Wrong Spec. Bad Application
Common Operating Issues
• Chemicals and Concentration
• Presence of Trace Chemicals
• Ambient Conditions
• Upset Conditions
• Size of Solid Presents
• Temperature Cycling
Chemical Environment Vulnerabilities
Chlorine/Halogens
• Permeation and diffusion.
• Aggressive ion exchange (valence number).
• Lots of vulnerable compounds.
• Used to make many composites/elastomers
Sulfur/Sulfur Compounds
• Hardening and brittle effect on steel/rubber (N/L steel, cross-linkage).
• Permeation and diffusion.
• Localized chemical attack.
• Improper anchoring and supporting (no point loads)
• Physical damage (striking/improper installation).
• Qualified experienced installers.
Above Ground Installation
Steel Tanks Internally Lined w/ FRP
Resin: Epoxy Novolac Resin for Tanks &
EN Formulated Steel Lining Systems
Case Study: Spent Sulfuric Acid Tanks
Environment:
Up to 80% Sulfuric Acid w/ Dissolved Cl2
Design Expectorations:
@ Max Temp = 140F
Lining Life = 10 - 15 yrs.
Recommend 5-yr. inspect intervals
Case Study: Spent Sulfuric Acid Service
Storage Tank in 36% phosphoric acid
Temp= Ambient
Age = 35+ years
Pulp/Paper Manufacturing
Design Expectorations:
Case Study: Phosphoric Acid Used in Water Treatment
“You can expect what you inspect- nothing more.”
- John H. Mallinson
• You must know what you require and know how to identify it.
• Quality Inspections are necessary.
Let the Results Speak for Themselves
Viable Contractor QC Program?
• Not viable due to motivation.
• Same figurehead= production/time efficiency
• Quality costs money
• In our experience, 90% of FRP field jobs are not delivered on time.
10x magnification of coating while raining
What Price Offers Service Life 10 years Life 15 years Life 30 years+
Service Rating Oilfield Service
Chemical Service/Treatment
ASME RTP-1 Tanks
Cost to Steel Ratio
1.2 Ratio 1.5 Ratio 2.0 Ratio
ASME RTP-1 DOES NOT GUARANTEE QUALITY (Requires Verification)
Issues Affecting Laminate Performance
Examples:
Poor curing (initial)
Diffusion
Applied stress
Embrittlement
Micro-cracking
Swelling
Impact
Environmental cycling
Aging (Time) Lack of Fusion and Poor Fit
Compliance
• Drawings
• Design Specifications
• Materials (lot numbers)
• Ambient Conditions
• Standards (ASME RTP-1)
• Verify Quality Control
• Pass/Fail Criteria
Quality Assurance Through Inspections
FINAL INSPECTION
Documents Review
Non Conformance
Reports
Cutouts
Resin Cure
Peel Adhesion Test (picture)
Dimensions and thickness
Holiday Testing
Quality is What Will Last
• Proper Material Selection for Service
• Comprehensive and descriptive specifications
• Qualify experienced applicators
• Quality assurance throughout the process
• Budget for Inspection on Coating/nonmetallic projects
Lessons Learned Keys to a Successful Project